Production facility layouts for automated controlled environment agriculture

ABSTRACT

Facility layouts and configurations for an automated crop production system for controlled environment agriculture. In particular implementations, the core of the facility comprises a controlled growth environment and a central processing system. The controlled growth environment includes systems for exposing crops housed in modules, such as grow towers, to controlled environmental conditions. The central processing system may include various stations and functionality both for preparing crop-bearing modules to be inserted in the controlled growth environment, for harvesting crops from the crop-bearing modules after they have been extracted from the controlled growth environment, and for cleaning or washing crop-bearing modules for re-use. The controlled growth environment may include vertical farming structure having vertical grow towers and associated conveyance mechanisms for moving the vertical grow towers along one or more grow lines. The conveyance mechanisms may include a return transfer mechanism that creates a return or u-shaped path for each grow line.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is the National Stage of InternationalApplication No. PCT/US2020/050593, filed Sep. 12, 2020, which claimspriority to U.S. provisional application Ser. No. 62/903,573 filed Sep.20, 2019 and 62/987,149 filed Mar. 9, 2020, both of which areincorporated herein by reference for all purposes.

BACKGROUND Field of the Disclosure

The disclosure relates generally to controlled environment agricultureand, more particularly, to production facility layouts andconfigurations for automated controlled environment crop productionsystems.

Description of Related Art

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches, which in and of themselves may also correspond toimplementations of the claimed technology.

During the twentieth century, agriculture slowly began to evolve from aconservative industry to a fast-moving high-tech industry. Global foodshortages, climate change and societal changes drove a move away frommanually-implemented agriculture techniques toward computer-implementedtechnologies. In the past, and in many cases still today, farmers onlyhad one growing season to produce the crops that would determine theirrevenue and food production for the entire year. However, this ischanging. With indoor growing as an option and with better access todata processing technologies, the science of agriculture has become moreagile. It is adapting and learning as new data is collected and insightsare generated.

Advancements in technology are making it feasible to control the effectsof nature with the advent of “controlled environment agriculture.”Improved efficiencies in space utilization, lighting, and a betterunderstanding of hydroponics, aeroponics, crop cycles, and advancementsin environmental control systems have allowed humans to better recreateenvironments conducive for agriculture crop growth with the goals ofgreater yield per square foot, better nutrition and lower cost.

US Patent Publication Nos. 2018/0014485 and 2018/0014486, both assignedto the assignee of the present disclosure and incorporated by referencein their entirety herein, describe environmentally controlled verticalfarming systems. The vertical farming structure (e.g., a verticalcolumn) may be moved about an automated conveyance system in an open orclosed-loop fashion, exposed to precision-controlled lighting, airflowand humidity, with ideal nutritional support.

US Patent Pub. No. US 2017/0055460 (“Brusatore”) describes a system forcontinuous automated growing of plants. A vertical array of plantsupporting arms extends radially from a central axis. Each arm includespot receptacles which receive the plant seedling, and liquid nutrientsand water. The potting arms are rotated beneath grow lamps andpollinating arms.

U.S. Pat. No. 2,244,677 to Cornell describes a plant production systemthat conveys vertical box-shaped frame within a greenhouse structure. Achain-drive mechanism conveys the vertical box-like frames in a trackwhere they are exposed to controlled environmental conditions. Cornell,however, does not contemplate automated processing or harvesting of thecrops grown in the box-like frames.

SUMMARY OF THE DISCLOSURE

The present disclosure is directed to facility layouts andconfigurations for an automated crop production system for controlledenvironment agriculture. In some implementations, the facility layoutsestablish consolidated utility and plant production zones that achieve avariety of operational and cost efficiencies. In particularimplementations, the core of the facility comprises a controlled growthenvironment and a central processing system. The controlled growthenvironment includes systems for exposing crops housed in modules, suchas grow towers, to controlled environmental conditions. The centralprocessing system may include various stations and functionality bothfor preparing crop-bearing modules to be inserted in the controlledgrowth environment, for harvesting crops from the crop-bearing modulesafter they have been extracted from the controlled growth environment,and for cleaning or washing crop-bearing modules for re-use. Theremaining aspects of the crop production facility—such as seedingstations, propagation facilities, packaging stations and storagefacilities—are arranged to achieve one or more desired efficienciesrelating to capital expenditures or operating costs associated with anautomated crop production facility.

The present disclosure is also directed to a vertical farming structurehaving vertical grow towers and associated conveyance mechanisms formoving the vertical grow towers along one or more grow lines through acontrolled environment, while being exposed to controlled conditions,such as lighting, airflow, humidity and nutritional support. The presentdisclosure describes a return transfer mechanism that creates a returnor u-shaped path for each grow line. The present disclosure alsodescribes an automated crop production system for controlled environmentagriculture that selectively routes grow towers through variousprocessing stages of an automated crop production system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a functional block diagram illustrating an example controlledenvironment agriculture system; and FIG. 1B is a functional blockdiagram illustrating a second example controlled environment agriculturesystem.

FIG. 2 is a perspective view of an example controlled environmentagriculture system.

FIGS. 3A and 3B are perspective views of an example grow tower.

FIG. 4A is a top view of an example grow tower; FIG. 4B is aperspective, top view of an example grow tower; FIG. 4C is an elevationview of a section of an example grow tower; and FIG. 4D is a sectional,elevation view of a portion of an example grow tower.

FIG. 5A is a perspective view of a portion of an example grow line; andFIG. 5B is a perspective view of an example tower hook.

FIG. 6 is an exploded, perspective view of a portion of an example growline and reciprocating cam mechanism.

FIG. 7A is a sequence diagram illustrating operation of an examplereciprocating cam mechanism; and FIG. 7B illustrates an alternative camchannel including an expansion joint.

FIG. 8 is a profile view of an example grow line and irrigation supplyline.

FIG. 9 is a side view of an example tower hook and integrated funnelstructure.

FIG. 10 is a profile view of an example grow line.

FIG. 11A is perspective view of an example tower hook and integratedfunnel structure; FIG. 11B is a section view of an example tower hookand integrated funnel structure; and FIG. 11C is a top view of anexample tower hook and integrated funnel structure.

FIG. 12 is an elevation view of an example carriage assembly.

FIG. 13A is an elevation view of the example carriage assembly from analternative angle to FIG. 12 ; and FIG. 13B is a perspective view of theexample carriage assembly.

FIG. 14 is a partial perspective view of an example automated laydownstation.

FIG. 15A is a partial perspective view of an example automated pickupstation; and

FIG. 15B is an alternative partial perspective view of the exampleautomated pickup station.

FIG. 16 is a perspective view of an example end effector for use in anautomated pickup or laydown station.

FIGS. 17A and 17B are partial, perspective views of an example gripperassembly mounted to an end effector for releasably grasping grow towers.

FIG. 18 is a partial perspective view of the example automated pickupstation.

FIG. 19 is partial perspective view of the example automated pickupstation that illustrates an example constraining mechanism thatfacilitates location of grow towers.

FIG. 20 is a side view of an example inbound harvester conveyor.

FIG. 21 is a functional block diagram of the stations and conveyancemechanisms of an example central processing system.

FIG. 22 is a partial perspective view of an example pickup conveyor.

FIG. 23A is a perspective view of an example harvester station; FIG. 23Bis a top view of an example harvester machine; and FIG. 23C is aperspective view of an example harvester machine.

FIG. 24A is an elevation view of an example end effector for use in atransplanter station; and FIG. 24B is a perspective view of atransplanter station.

FIG. 25 illustrates an example of a computer system that may be used toexecute instructions stored in a non-transitory computer readable medium(e.g., memory) in accordance with embodiments of the disclosure.

FIG. 26A is an elevation view of an example return transfer mechanism;and FIG. 26B is an enlarged view of an example carriage for the returntransfer mechanism.

FIG. 27 is a schematic diagram illustrating an example controlledenvironment agriculture system that includes multiple growthenvironments.

FIG. 28 is a functional block diagram illustrating an example cropproduction facility layout.

FIG. 29 is a schematic diagram illustrating an alternative view of theproduction facility layout of FIG. 28 .

FIG. 30 is an enlarged view of pre-harvest buffers contained within apre-harvest space of the production facility depicted in FIGS. 28 and 29.

DETAILED DESCRIPTION

The present description is made with reference to the accompanyingdrawings, in which various example embodiments are shown. However, manydifferent example embodiments may be used, and thus the descriptionshould not be construed as limited to the example embodiments set forthherein. Rather, these example embodiments are provided so that thisdisclosure will be thorough and complete. Various modifications to theexemplary embodiments will be readily apparent to those skilled in theart, and the generic principles defined herein may be applied to otherembodiments and applications without departing from the spirit and scopeof the disclosure. Thus, this disclosure is not intended to be limitedto the embodiments shown, but is to be accorded the widest scopeconsistent with the principles and features disclosed herein.

Operating cost and capital expenditure concerns are key drivers tocommercial implementation of large-scale controlled environmentagriculture. Commercial scale, indoor crop production facilities includea large array of processing stations and equipment. For example, indoorcrop production facilities may include stations and related equipmentto: fill plug trays with soil and seed them; grow crops from seed to astage ready for transplant; transplant the seedlings to a crop-holdingmodule; transfer the crop-holding module to a growth environment;harvest crops in the crop-holding module; clean and package theharvested crop; and store the harvested crop. Commercial scalefacilities may also include loading bays and inventory handlingmechanisms to receive inbound supplies used in operating the facilityand to ship out the resulting crop. Arranging these stations andequipment in an efficient manner can be a complex task and is extremelyimportant to the success of a commercial-scale facility. Factors thatthis disclosure considers to increase cost efficiency include spaceutilization and total flow distance of product from seed stage toharvest and packaging. Other factors considered include the total lengthof materials required to construction the facility (such as total lengthof walls, HVAC ducting and the like), and the distances that facilityworkers are required to travel during standard processing operations.These factors, as well as equipment layout clearances and local fire andbuilding regulations, may combine to yield a crop production facilitylayout.

FIGS. 28 and 29 set forth an example production facility layout thatachieves a variety of operational and cost efficiencies. For didacticpurposes, the following describes a vertical farm production systemconfigured for high density growth and crop yield that can be includedin the production facility layout described herein. FIGS. 1A and 2illustrate a controlled environment agriculture system 10 according toone possible embodiment of the invention. At a high level, the system 10may include an environmentally-controlled growing chamber 20 and acentral processing facility 30. The central processing facility 30 maybe a clean room environment to keep contaminants and pollutants withinacceptable limits. Air filtration, transfer and other systems may beemployed to effect a clean room environment to meet required food safetystandards.

The growing chamber 20 may contain one to a plurality of vertical growlines 202 that include conveyance systems to translate grow towers 50along the grow lines 202 within the growing chamber 20. The crops orplants species that may be grown may be gravitropic, geotropic and/orphototropic, or some combination thereof. The crops or plant species mayvary considerably and include various leaf vegetables, fruitingvegetables, flowering crops, fruits and the like. The controlledenvironment agriculture system 10 may be configured to grow a singlecrop type at a time or to grow multiple crop types concurrently.

The system 10 may also include conveyance systems for moving the growtowers 50 in a circuit throughout the crop's growth and processingcycle, the circuit comprising a staging area configured for loading thegrow towers 50 into and out a grow line 202. The central processingsystem 30 may include one or more conveyance mechanisms for directinggrow towers 50 to stations in the central processing system 30—e.g.,stations for loading plants into, and harvesting crops from, the growtowers 50.

Each grow tower 50 is configured for containing plant growth media thatsupports a root structure of at least one crop plant growing therein.Each grow tower 50 is also configured to releasably attach to a growline 202 in a vertical orientation and move along the grow line 202within growth environment 20 during a growth phase. Together, the growlines 202 contained within the growth environment 20 and the stations ofthe central processing system 30 (including associated conveyancemechanisms) can be arranged in a production circuit under control of oneor more computing systems.

The growth environment 20 may include light emitting sources positionedat various locations between and along the grow lines 202 of thevertical tower conveyance system 200. The light emitting sources can bepositioned laterally relative to the grow towers 50 in the grow line 202and configured to emit light toward the lateral faces of the grow towers50 that include openings from which crops grow. The light emittingsources may be incorporated into a water-cooled, LED lighting system asdescribed in U.S. Publ. No. 2017/0146226A1, the disclosure of which isincorporated by reference herein. In such an embodiment, the LED lightsmay be arranged in a bar-like structure. The bar-like structure may beplaced in a vertical orientation to emit light laterally tosubstantially the entire length of adjacent grow towers 50. Multiplelight bar structures may be arranged in the growth environment 20 alongand between the grow lines 202. Other lighting systems andconfigurations may be employed. For example, the light bars may bearranged horizontally between grow lines 202.

The growth environment 20 may also include a nutrient supply systemconfigured to supply an aqueous nutrient solution to the crops as theytranslate through the growth chamber 20. As discussed in more detailbelow, the nutrient supply system may apply aqueous nutrient solution tothe top of the grow towers 50. Gravity may cause the solution to traveldown the vertically-oriented grow tower 50 and through the lengththereof to supply solution to the crops disposed along the length of thegrow tower 50. The growth environment 20 may also include an airflowsource configured to, when a tower is mounted to a grow line 202, directairflow in the lateral growth direction of growth and through anunder-canopy of the growing plant, so as to disturb the boundary layerof the under-canopy of the growing plant. In other implementations,airflow may come from the top of the canopy or orthogonal to thedirection of plant growth. The growth environment 20 may also include acontrol system, and associated sensors, for regulating at least onegrowing condition, such as air temperature, airflow speed, relative airhumidity, and ambient carbon dioxide gas content. The control system mayfor example include such sub-systems as HVAC units, chillers, fans andassociated ducting and air handling equipment. Grow towers 50 may haveidentifying attributes (such as bar codes or RFID tags). The controlledenvironment agriculture system 10 may include corresponding sensors andprogramming logic for tracking the grow towers 50 during various stagesof the farm production cycle and/or for controlling one or moreconditions of the growth environment. The operation of control systemand the length of time towers remain in growth environment can varyconsiderably depending on a variety of factors, such as crop type andother factors.

As discussed above, grow towers 50 with newly transplanted crops orseedlings are transferred from the central processing system 30 into thevertical tower conveyance system 200. Conveyance mechanisms move thegrow towers 50 along respective grow lines 202 in growth environment 20in a controlled fashion, as discussed in more detail below. Cropsdisposed in grow towers 50 are exposed to the controlled conditions ofgrowth environment (e.g., light, temperature, humidity, air flow,aqueous nutrient supply, etc.). The control system is capable ofautomated adjustments to optimize growing conditions within the growthchamber 20 to make continuous improvements to various attributes, suchas crop yields, visual appeal and nutrient content. In addition, USPatent Publication Nos. 2018/0014485 and 2018/0014486 describeapplication of machine learning and other operations to optimize growconditions in a vertical farming system. In some implementations,environmental condition sensors may be disposed on grow towers 50 or atvarious locations in growth environment 20. When crops are ready forharvesting, grow towers 50 with crops to be harvested are transferredfrom the growth environment 20 to the central processing system 30 forharvesting and other processing operations.

Central processing system 30, as discussed in more detail below, mayinclude processing stations directed to injecting seedlings into growsites located in the towers 50, harvesting crops from towers 50, andcleaning towers 50 that have been harvested. Central processing system30 may also include conveyance mechanisms that move towers 50 betweensuch processing stations. For example, as FIG. 1A illustrates, centralprocessing system 30 may include harvester station 32, washing station34, and transplanter station 36. Harvester station 32 may depositharvested crops into food-safe containers and may include a conveyancemechanism for conveying the containers to post-harvesting facilities(e.g., preparation, washing, packaging and storage) that are beyond thescope of this disclosure.

Controlled environment agriculture system 10 may also include one ormore conveyance mechanisms for transferring grow towers 50 betweengrowth environment 20 and central processing system 30. In theimplementation shown, the stations of central processing system 30operate on grow towers 50 in a horizontal orientation. In oneimplementation, an automated pickup station 43, and associated controllogic, may be operative to releasably grasp a tower in a horizontalorientation from a loading location, rotate the tower to a verticalorientation and attach the tower to a transfer station for insertioninto a selected grow line 202 of the growth environment 20. On the otherend of growth environment 20, automated laydown station 41, andassociated control logic, may be operative to releasably grasp and movea vertically-oriented grow tower 50 from a buffer location, rotate thegrow tower 50 to a horizontal orientation and place it on a conveyancesystem for loading into harvester station 32. In some implementations,if a grow tower 50 is rejected due to quality control concerns, theconveyance system may bypass the harvester station 32 and carry the growtower to washing station 34 (or some other station). The automatedlaydown and pickup stations 41 and 43 may each comprise a six-degrees offreedom robotic arm, such as a FANUC robot. The stations 41 and 43 mayalso include end effectors for releasably grasping grow towers 50 atopposing ends.

In one implementation, a transfer conveyance mechanism 47 may include apower-and-free conveyor system including a plurality of carriages, atrack system and a drive system that conveys the carriages, each loadedwith a grow tower 50, from the automated pickup station 43 to a selectedgrow line 202. In one implementation, growth environment 20 includes atower injection interface 38 to allow a carriage 1202 of the transferconveyance mechanism 47 to pass through the physical barrier of growthenvironment 20. In one implementation, tower injection interface 38comprises a vertical slot (sufficient in length to accommodate a growtower 50) and a sliding door that opens to permit a grow tower 50 topass through the vertical slot. System 10 may include sensors (such asRFID or bar code sensors) to identify a given grow tower 50 and, undercontrol logic, select a grow line 202 for the grow tower 50. Thetransfer conveyance mechanism 47 may also convey a grow tower 50 from agrow line 202 to the automated laydown station 41. Tower extractioninterface 39 includes a vertical slot in growth environment and asliding door to permit transfer conveyance mechanism 47 to convey atower 50 from growth environment. Particular algorithms for grow lineselection can vary considerably depending on a number of factors and isbeyond the scope of this disclosure.

Growth environment 20 may also include automated loading and unloadingmechanisms for inserting grow towers 50 into selected grow lines 202 andunloading grow towers 50 from the grow lines 202. For example, after thetransfer conveyance mechanism 47 has transported a grow tower 50 to aselected grow line 202, one or more linear actuators may push (orotherwise transfer) the grow tower 50 onto the grow line 202. Similarly,one or more linear actuators that push or pull (or otherwise transfer)grow towers from a grow line 202 onto a carriage of transfer conveyancemechanism 47, which conveys the carriages 1202 from the grow line 202 tothe automated laydown station 41.

FIG. 12 illustrates a carriage 1202 that may be used in a powered andfree conveyor mechanism. In the implementation shown, carriage 1202includes hook 1204 that engages hook 52 attached to a grow tower 50. Alatch assembly 1206 may secure the grow tower 50 while it is beingconveyed to and from various locations in the system. In oneimplementation, transfer conveyance mechanism 47 may be configured witha sufficient track distance to establish a zone where grow towers 50 maybe buffered. For example, transfer conveyance mechanism 47 may becontrolled such that it unloads a set of towers 50 to be harvested untocarriages 1202 that are moved to a buffer region of the track. On theother end, automated pickup station 43 may load a set of towers to beinserted into growth environment 20 onto carriages 1202 disposed inanother buffer region of the track.

Grow Towers

Grow towers 50 provide the sites for individual crops to grow in thesystem. As FIGS. 3A and 3B illustrate, a hook 52 attaches to the top ofgrow tower 50. Hook 52 allows grow tower 50 to be supported by a growline 202 when it is inserted into the vertical tower conveyance system200. In one implementation, a grow tower 50 measures 5.172 meters long,where the extruded length of the tower is 5.0 meters, and the hook is0.172 meters long. The extruded rectangular profile of the grow tower50, in one implementation, measures 57 mm×93 mm (2.25″×3.67″). The hook52 can be designed such that its exterior overall dimensions are notgreater than the extruded profile of the grow tower 50. The foregoingdimensions are for didactic purposes. The dimensions of grow tower 50can be varied depending on a number of factors, such as desiredthroughput, overall size of the system, and the like. For example, agrow tower 50 may be 8 to 10 meters in length or longer.

Grow towers 50 may include a set of grow sites 53 arrayed along at leastone face of the grow tower 50. In the implementation shown in FIG. 4A,grow towers 50 include grow sites 53 on opposing faces such that plantsprotrude from opposing sides of the grow tower 50. Transplanter station36 may transplant seedlings into empty grow sites 53 of grow towers 50,where they remain in place until they are fully mature and ready to beharvested. In one implementation, the orientation of the grow sites 53are perpendicular to the direction of travel of the grow towers 50 alonggrow line 202. In other words, when a grow tower 50 is inserted into agrow line 202, plants extend from opposing faces of the grow tower 50,where the opposing faces are parallel to the direction of travel.Although a dual-sided configuration is preferred, the invention may alsobe utilized in a single-sided configuration where plants grow along asingle face of a grow tower 50.

U.S. application Ser. No. 15/968,425 filed on May 1, 2018 which isincorporated by reference herein for all purposes, discloses an exampletower structure configuration that can be used in connection withvarious embodiments of the invention. In the implementation shown, growtowers 50 may each consist of three extrusions which snap together toform one structure. As shown, the grow tower 50 may be a dual-sidedhydroponic tower, where the tower body 103 includes a central wall 56that defines a first tower cavity 54 a and a second tower cavity 54 b.FIG. 4B provides a perspective view of an exemplary dual-sided,multi-piece hydroponic grow tower 50 in which each front face plate 101is hingeably coupled to the tower body 103. In FIG. 4B, each front faceplate 101 is in the closed position. The cross-section of the towercavities 54 a, 54 b may be in the range of 1.5 inches by 1.5 inches to 3inches by 3 inches, where the term “tower cavity” refers to the regionwithin the body of the tower and behind the tower face plate. The wallthickness of the grow towers 50 maybe within the range of 0.065 to 0.075inches. A dual-sided hydroponic tower, such as that shown in FIGS. 4Aand 4B, has two back-to-back cavities 54 a and 54 b, each preferablywithin the noted size range. In the configuration shown, the grow tower50 may include (i) a first V-shaped groove 58 a running along the lengthof a first side of the tower body 103, where the first V-shaped grooveis centered between the first tower cavity and the second tower cavity;and (ii) a second V-shaped groove 58 b running along the length of asecond side of the tower body 103, where the second V-shaped groove iscentered between the first tower cavity and the second tower cavity. TheV-shaped grooves 58 a, 58 b may facilitate registration, alignmentand/or feeding of the towers 50 by one or more of the stations incentral processing system 30. U.S. application Ser. No. 15/968,425discloses additional details regarding the construction and use oftowers that may be used in embodiments of the invention. Anotherattribute of V-shaped grooves 58 a, 58 b is that they effectively narrowthe central wall 56 to promote the flow of aqueous nutrient solutioncentrally where the plant's roots are located. Other implementations arepossible. For example, a grow tower 50 may be formed as a unitary,single extrusion, where the material at the side walls flex to provide ahinge and allow the cavities to be opened for cleaning. U.S. applicationSer. No. 16/577,322 filed on Sep. 20, 2019 which is incorporated byreference herein for all purposes, discloses an example grow tower 50formed by a single extrusion.

As FIGS. 4C and 4D illustrate, grow towers 50 may each include aplurality of cut-outs 105 for use with a compatible plug holder 158,such as the plug holder disclosed in any one of co-assigned andco-pending U.S. patent application Ser. Nos. 15/910,308, 15/910,445 and15/910,796, each filed on 2 Mar. 2018, the disclosures of which isincorporated herein for any and all purposes. As shown, the plug holders158 may be oriented at a 45-degree angle relative to the front faceplate 101 and the vertical axis of the grow tower 50. It should beunderstood, however, that tower design disclosed in the presentapplication is not limited to use with this particular plug holder ororientation, rather, the towers disclosed herein may be used with anysuitably sized and/or oriented plug holder. As such, cut-outs 105 areonly meant to illustrate, not limit, the present tower design and itshould be understood that the present invention is equally applicable totowers with other cut-out designs. Plug Holder 158 may be ultrasonicallywelded, bonded, or otherwise attached to tower face 101.

The use of a hinged front face plate simplifies manufacturing of growtowers, as well as tower maintenance in general and tower cleaning inparticular. For example, to clean a grow tower 50 the face plates 101are opened from the body 103 to allow easy access to the body cavity 54a or 54 b. After cleaning, the face plates 101 are closed. Since theface plates remain attached to the tower body 103 throughout thecleaning process, it is easier to maintain part alignment and to insurethat each face plate is properly associated with the appropriate towerbody and, assuming a double-sided tower body, that each face plate 101is properly associated with the appropriate side of a specific towerbody 103. Additionally, if the planting and/or harvesting operations areperformed with the face plate 101 in the open position, for thedual-sided configuration both face plates can be opened andsimultaneously planted and/or harvested, thus eliminating the step ofplanting and/or harvesting one side and then rotating the tower andplanting and/or harvesting the other side. In other embodiments,planting and/or harvesting operations are performed with the face plate101 in the closed position.

Other implementations are possible. For example, grow tower 50 cancomprise any tower body that includes a volume of medium or wickingmedium extending into the tower interior from the face of the tower(either a portion or individual portions of the tower or the entirety ofthe tower length. For example, U.S. Pat. No. 8,327,582, which isincorporated by reference herein, discloses a grow tube having a slotextending from a face of the tube and a grow medium contained in thetube. The tube illustrated therein may be modified to include a hook 52at the top thereof and to have slots on opposing faces, or one slot on asingle face.

Vertical Tower Conveyance System & Return Path Grow Lines

FIG. 5A illustrates a portion of a grow line 202 disposed within growthenvironment 20. In one implementation, the growth environment 20 maycontain a plurality of grow lines 202 arranged in a parallelconfiguration. As FIG. 1A illustrates, each grow line 202 may have asubstantially u-shaped travel path including a first path section 202 aand a second return path section 202 b. As discussed below, a returntransfer mechanism 220 transfers grow towers 50 from the end of thefirst path section 202 a to the second return path section 202 b. Asdiscussed above, transfer conveyance mechanism 47 may selectively load agrow tower on a first path section 202 a of a selected grow line 202,and unload grow towers 50 from the end of a return path section 202 b ofa grow line 202 under automated control systems. As FIG. 5A shows, eachpath section 202 a, 202 b of a grow line 202 supports a plurality ofgrow towers 50. In one implementation, a grow line 202 may be mounted tothe ceiling (or other support) of the grow structure by a bracket forsupport purposes. As FIGS. 5A and 5B show, hook 52 hooks into, andattaches, a grow tower 50 to a grow line 202, thereby supporting thetower 50 in a vertical orientation as it is translated through thegrowth environment 20.

FIG. 10 illustrates the cross section or extrusion profile of a growline 202, according to one possible implementation of the invention. Thegrow line 202 may be an aluminum extrusion. The bottom section of theextrusion profile of the grow line 202 includes an upward facing groove1002. As FIG. 9 shows, hook 52 of a grow tower 50 includes a main body53 and corresponding member 58 that engages groove 1002 as shown inFIGS. 5A and 8 . These hooks allow the grow towers 50 to hook into thegroove 1002 and slide along the grow line 202 as discussed below.Conversely, grow towers 50 can be manually unhooked from a grow line 202and removed from production. This ability may be necessary if a crop ina grow tower 50 becomes diseased so that it does not infect othertowers. In one possible implementation, the width of groove 1002 (forexample, 13 mm) is an optimization between two different factors. First,the narrower the groove the more favorable the binding rate and the lesslikely grow tower hooks 52 are to bind. Conversely, the wider the groovethe slower the grow tower hooks wear due to having a greater contactpatch. Similarly, the depth of the groove, for example 10 mm, may be anoptimization between space savings and accidental fallout of towerhooks.

Hooks 52 may be injection-molded plastic parts. In one implementation,the plastic may be polyvinyl chloride (PVC), acrylonitrile butadienestyrene (ABS), or an Acetyl Homopolymer (e.g., Delrin® sold by DuPontCompany). The hook 52 may be solvent bonded to the top of the grow tower50 and/or attached using rivets or other mechanical fasteners. Thegroove-engaging member 58 which rides in the rectangular groove 1002 ofthe grow line 202 may be a separate part or integrally formed with hook52. If separate, this part can be made from a different material withlower friction and better wear properties than the rest of the hook,such as ultra-high-molecular weight polyethylene or acetal. To keepassembly costs low, this separate part may snap onto the main body ofthe hook 52. Alternatively, the separate part also be over-molded ontothe main body of hook 52.

As FIGS. 6 and 10 illustrate, the top section of the extrusion profileof grow line 202 contains a downward facing t-slot 1004. Linear guidecarriages 610 (described below) ride within the t-slot 1004. The centerportion of the t-slot 1004 may be recessed to provide clearance fromscrews or over-molded inserts which may protrude from the carriages 610.Each grow line 202 can be assembled from a number of separatelyfabricated sections. In one implementation, sections of grow line 202are currently modeled in 6-meter lengths. Longer sections reduce thenumber of junctions but are more susceptible to thermal expansion issuesand may significantly increase shipping costs. Additional features notcaptured by the Figures include intermittent mounting holes to attachthe grow line 202 to the ceiling structure and to attach irrigationlines. Interruptions to the t-slot 1004 may also be machined into theconveyor body. These interruptions allow the linear guide carriages 610to be removed without having to slide them all the way out the end of agrow line 202.

At the junction between two sections of a grow line 202, a block 612 maybe located in the t-slots 1004 of both conveyor bodies. This blockserves to align the two grow line sections so that grow towers 50 mayslide smoothly between them. Alternative methods for aligning sectionsof a grow line 202 include the use of dowel pins that fit into dowelholes in the extrusion profile of the section. The block 612 may beclamped to one of the grow line sections via a set screw, so that thegrow line sections can still come together and move apart as the resultof thermal expansion. Based on the relatively tight tolerances and smallamount of material required, these blocks may be machined. Bronze may beused as the material for such blocks due to its strength, corrosionresistance, and wear properties.

In one implementation, the vertical tower conveyance system 200 utilizesa reciprocating linear ratchet and pawl structure (hereinafter referredto as a “reciprocating cam structure or mechanism”) to move grow towers50 along a path section 202 a, 202 b of a grow line 202. In oneimplementation, each path section 202 a, 202 b includes a separatereciprocating cam structure and associated actuators. FIGS. 5A, 6 and 7illustrate one possible reciprocating cam mechanism that can be used tomove grow towers 50 across grow lines 202. Pawls or “cams” 602physically push grow towers 50 along grow line 202. Cams 602 areattached to cam channel 604 (see below) and rotate about one axis. Onthe forward stroke, the rotation is limited by the top of the camchannel 604, causing the cams 602 to push grow towers 50 forward. On thereserve or back stroke, the rotation is unconstrained, thereby allowingthe cams to ratchet over the top of the grow towers 50. In this way, thecam mechanism can stroke a relatively short distance back and forth, yetgrow towers 50 always progress forward along the entire length of a growline 202. A control system, in one implementation, controls theoperation of the reciprocating cam mechanism of each grow line 202 tomove the grow towers 50 according to a programmed growing sequence. Inbetween movement cycles, the actuator and reciprocating cam mechanismremain idle.

The pivot point of the cams 602 and the means of attachment to the camchannel 604 consists of a binding post 606 and a hex head bolt 608;alternatively, detent clevis pins may be used. The hex head bolt 608 ispositioned on the inner side of the cam channel 604 where there is notool access in the axial direction. Being a hex head, it can be accessedradially with a wrench for removal. Given the large number of camsneeded for a full-scale farm, a high-volume manufacturing process suchas injection molding is suitable. ABS is suitable material given itsstiffness and relatively low cost. All the cams 602 for a correspondinggrow line 202 are attached to the cam channel 604. When connected to anactuator, this common beam structure allows all cams 602 to stroke backand forth in unison. The structure of the cam channel 604, in oneimplementation, is a downward facing u-channel constructed from sheetmetal. Holes in the downward facing walls of cam channel 604 providemounting points for cams 602 using binding posts 606.

Holes of the cam channel 604, in one implementation, are spaced at 12.7mm intervals. Therefore, cams 602 can be spaced relative to one anotherat any integer multiple of 12.7 mm, allowing for variable grow towerspacing with only one cam channel. The base of the cam channel 604limits rotation of the cams during the forward stroke. All degrees offreedom of the cam channel 604, except for translation in the axialdirection, are constrained by linear guide carriages 610 (describedbelow) which mount to the base of the cam channel 604 and ride in thet-slot 1004 of the grow line 202. Cam channel 604 may be assembled fromseparately formed sections, such as sections in 6-meter lengths. Longersections reduce the number of junctions but may significantly increaseshipping costs. Thermal expansion is generally not a concern because thecam channel is only fixed at the end connected to the actuator. Giventhe simple profile, thin wall thickness, and long length needed, sheetmetal rolling is a suitable manufacturing process for the cam channel.Galvanized steel is a suitable material for this application.

Linear guide carriages 610 are bolted to the base of the cam channels604 and ride within the t-slots 1004 of the grow lines 202. In someimplementations, one carriage 610 is used per 6-meter section of camchannel. Carriages 610 may be injection molded plastic for low frictionand wear resistance. Bolts attach the carriages 610 to the cam channel604 by threading into over molded threaded inserts. If select cams 602are removed, these bolts are accessible so that a section of cam channel604 can be detached from the carriage and removed.

Sections of cam channel 604 are joined together with pairs of connectors616 at each joint; alternatively, detent clevis pins may be used.Connectors 616 may be galvanized steel bars with machined holes at 20 mmspacing (the same hole spacing as the cam channel 604). Shoulder bolts618 pass through holes in the outer connector, through the cam channel604, and thread into holes in the inner connector. If the shoulder boltsfall in the same position as a cam 602, they can be used in place of abinding post. The heads of the shoulder bolts 618 are accessible so thatconnectors and sections of cam channel can be removed.

In one implementation, cam channel 604 attaches to a linear actuator,which operates in a forward and a back stroke. A suitable linearactuator may be the T13-B4010MS053-62 actuator offered by Thomson, Inc.of Redford, Virginia; however, the reciprocating cam mechanism describedherein can be operated with a variety of different actuators. The linearactuator may be attached to cam channel 604 at the off-loading end of apath section 202 a, 202 b of a grow line 202, rather than theon-boarding end. In such a configuration, cam channel 604 is undertension when loaded by the towers 50 during a forward stroke of theactuator (which pulls the cam channel 604) which reduces risks ofbuckling. FIG. 7A illustrates operation of the reciprocating cammechanism according to one implementation of the invention. In step A,the linear actuator has completed a full back stroke; as FIG. 7Aillustrates, one or more cams 602 may ratchet over the hooks 52 of agrow tower 50. Step B of FIG. 7A illustrates the position of cam channel604 and cams 602 at the end of a forward stroke. During the forwardstroke, cams 602 engage corresponding grow towers 50 and move them inthe forward direction along grow line 202 as shown. Step C of FIG. 7Aillustrates how a new grow tower 50 (Tower 0) may be inserted onto agrow line 202 and how the last tower (Tower 9) may be removed. Step Dillustrates how cams 602 ratchet over the grow towers 50 during a backstroke, in the same manner as Step A. The basic principle of thisreciprocating cam mechanism is that reciprocating motion from arelatively short stroke of the actuator transports towers 50 in onedirection along the entire length of the grow line 202. Morespecifically, on the forward stroke, all grow towers 50 on a grow line202 are pushed forward one position. On the back stroke, the cams 602ratchet over an adjacent tower one position back; the grow towers remainin the same location. As shown, when a grow line 202 is full, a new growtower 50 may be loaded and a last tower unloaded after each forwardstroke of the linear actuator. In some implementations, the top portionof the hook 52 (the portion on which the cams push), is slightlynarrower than the width of a grow tower 50. As a result, cams 602 canstill engage with the hooks 52 when grow towers 50 are spacedimmediately adjacent to each other. FIG. 7A shows 9 grow towers fordidactic purposes. A grow line 202 can be configured to be quite long(for example, 40 meters) allowing for a much greater number of towers 50on a grow line 202 (such as 400-450). Other implementations arepossible. For example, the minimum tower spacing can be set equal to orslightly greater than two times the side-to-side distance of a growtower 50 to allow more than one grow tower 50 to be loaded onto a growline 202 in each cycle.

Still further, as shown in FIG. 7A, the spacing of cams 602 along thecam channel 604 can be arranged to effect one-dimensional plant indexingalong the grow line 202. In other words, the cams 602 of thereciprocating cam mechanism can be configured such that spacing betweentowers 50 increases as they travel along a grow line 202. For example,spacing between cams 602 may gradually increase from a minimum spacingat the beginning of a grow line to a maximum spacing at the end of thegrow line 202. This may be useful for spacing plants apart as they growto increase light interception and provide spacing, and, throughvariable spacing or indexing, increasing efficient usage of the growthchamber 20 and associated components, such as lighting. In oneimplementation, the forward and back stroke distance of the linearactuator is equal to (or slightly greater than) the maximum towerspacing. During the back stroke of the linear actuator, cams 602 at thebeginning of a grow line 202 may ratchet and overshoot a grow tower 50.On the forward stroke, such cams 602 may travel respective distancesbefore engaging a tower, whereas cams located further along the growline 202 may travel shorter distances before engaging a tower or engagesubstantially immediately. In such an arrangement, the maximum towerspacing cannot be two times greater than the minimum tower spacing;otherwise, a cam 602 may ratchet over and engaging two or more growtowers 50. If greater maximum tower spacing is desired, an expansionjoint may be used, as illustrated in FIG. 7B. An expansion joint allowsthe leading section of the cam channel 604 to begin traveling before thetrailing end of the cam channel 604, thereby achieving a long stroke. Inparticular, as FIG. 7B shows, expansion joint 710 may attach to sections604 a and 604 b of cam channel 604. In the initial position (702), theexpansion joint 710 is collapsed. At the beginning of a forward stroke(704), the leading section 604 a of cam channel 604 moves forward (asthe actuator pulls on cam channel 604), while the trailing section 604 bremains stationary. Once the bolt bottoms out on the expansion joint 710(706), the trailing section 604 of cam channel 604 begins to moveforward as well. On the back stroke (708), the expansion joint 710collapses to its initial position.

Other implementations for moving vertical grow towers 50 may beemployed. For example, a lead screw mechanism may be employed. In suchan implementation, the threads of the lead screw engage hooks 52disposed on grow line 202 and move grow towers 50 as the shaft rotates.The pitch of the thread may be varied to achieve one-dimensional plantindexing. In another implementation, a belt conveyor include paddlesalong the belt may be employed to move grow towers 50 along a grow line202. In such an implementation, a series of belt conveyors arrangedalong a grow line 202, where each belt conveyor includes a differentspacing distance among the paddles to achieve one-dimensional plantindexing. In yet other implementations, a power-and-free conveyor may beemployed to move grow towers 50 along a grow line 202.

A return transfer mechanism 220 transfers grow towers 50 from a firstpath section 202 a to the second return path section 202 b, causing growtowers 50 to travel in a substantially u-shaped path. In theimplementation shown in FIG. 1A, each grow line 202 includes a separatereturn transfer mechanism 220. In other implementations, a single returntransfer mechanism 220 can be configured to span across and servemultiple grow lines 202. As FIG. 26A illustrates, in one implementation,the return transfer mechanism 220 comprises a belt-driven actuator 2602that drives a carriage 2604 along a track 2608 using a servo motor 2606.The MSA series of actuators offered by Macron Dynamics, Inc. of Croydon,PA are examples of belt-driven actuators suitable for use in variousimplementations disclosed herein. Carriage 2604 includes a lower section2610 that includes a hook receiver section 2612 including a groove 2618that engages hook 52 attached to a grow tower 50. Receiver section 2612may also have a latch 2614 which closes down on the outer side of thegrow tower 50 to prevent a grow tower 50 from sliding off duringacceleration or deceleration associated with return transfer conveyance.In one implementation, a controller may control return transfermechanism 220 to move carriage 2604 such that groove 2618 aligns withthe track of a first path section 202 a of a select grow line 202. Alinear actuator attached proximally to the offload end of the first pathsection 202 a can push a grow tower 50 onto receiver section 2612.Alternatively, the reciprocating cam mechanism associated with firstpath section 202 a can be configured to push the grow tower 50 ontoreceiver section 2612. When hook 52 of grow tower 50 is engaged inreceiver section 2612, a controller may cause servo motor 2606 to movecarriage 2604 to the onload end of return path section 202 b of the growline 202 such that the hook 52 is aligned with the track. A secondlinear actuator attached proximally to the onload end of the return pathsection 202 b may slide the grow tower 50 from receive section 2612 ontothe track. Alternatively, the reciprocating cam mechanism associatedwith return path section 202 b can be configured to transfer the growtower 50 from receiver section 2612. An advantage associated with thereturn transfer mechanism described above is that the orientation ofhook 52 does not change. This allows for carriage 1202 of transferconveyance mechanism 47 to load a grow tower 50 onto a grow line 202 andextract a grow tower 50 from the grow line without having to rotate thereceive section 1204 of the carriage 1202.

As discussed above, the length of the track 2608 is configured to spaneither a first path section 202 a and a return path section 202 b, or tospan across multiple grow lines 202 to allow a single return transfermechanism 220 to operate in connection with these grow lines 202(schematically, this can be envisioned by extending the individualelements 220 into a return transfer mechanism with a single contiguoustrack). In other implementations, other types of return transfermechanisms 220 may be configured for each grow line 202. For example,pneumatic actuators can be employed to move a carriage similar tocarriage 2604 above along a track back and forth as required to performthe transfer operations described herein. Other return transfermechanisms can also be employed. For example, the return transfermechanism may comprise a swinging arm that engages a grow tower 50 atthe offload end of first path section 202 a and swings 180 degrees totranslate the grow tower 50 to the onload end of the return path section202 b. In another implementation, return transfer mechanism 220 mayinclude a semi-circular track section spanning the first and second pathsections 202 a, 202 b of grow line 202. In such an implementation, awheel including paddles can push grow towers around the semi-circulartrack section with each movement cycle of the grow line 202. These twoforegoing implementations, however, switch the orientation of hook 52,requiring carriage 1202 to include a swivel mechanism.

FIGS. 1A and 21 schematically illustrates how central processing system30 may be configured to work in connection with a system that includes areturn path grow line 202. For example, automated transfer station 41may extract a grow tower 50 from conveyance mechanism 47 and place thegrow tower horizontally on infeed conveyor 1420. Harvesting station 32may process the grow tower 50. The processed grow tower 50 may be routedback to growth environment 20 or to other stations of the centralprocessing system, such as washing station 34 or back to automatedtransfer station 42. In either case, automated pickup station 43 mayplace the grow tower 50 onto a carriage 1202 of transfer conveyancemechanism 47, as discussed below. In the implementations discussedabove, using a return path in the grow line 202 means that grow towers50 can be injected into, and extracted from, the same side of the growthenvironment 20. This configuration allows for potential reductions insystem cost by eliminating certain components, such as separate transfermechanisms for loading and unloading grow towers from the grow lines202. In some implementations, path sections 202 a and 202 b aresubstantially horizontal. In other implementations, one or both of pathsections 202 a and 202 b may be downwardly sloped in their respectivedirections of travel.

FIG. 1B illustrates another example farm system layout. In the systemillustrated in FIG. 1B, one automated pickup and laydown station 42 isused instead of separate stations 41 and 43. Similar to the systemillustrated in FIG. 1A, transfer conveyance mechanism 47 transfers growtowers 50 between growth environment 20 and station 42. The orientationof the various components of central processing system 30 may alsochange. For example, conveyor 102 may transfer a horizontally-orientedtower to harvester 32 for processing. Conveyor 104 in connection withtransfer station 105 may transfer the processed grow tower to conveyor106. Conveyor 106 may feed the grow tower 50 into washing station 34 or,in a cut-again workflow, transfer the grow tower 50 back to station 42for insertion into the growth environment. Transfer conveyor 107 maytransfer a grow tower 50 from washing station 34 to a conveyor thatfeeds transplanter station 36. Otherwise, the central processing system30 operates in a substantially similar manner to the system described inconnection with FIG. 1A.

FIGS. 1A and 1B illustrate systems where all grow lines 202 of system 10are contained within a single growth environment 20. FIG. 27 illustrateshow a single central processing system 30 may operate in connection withmultiple growth environments 20 a-g. Each of the growth environments 20a-g may be separately controlled to support optimized growing for avariety of different crop types. In the implementation shown, transferconveyance mechanism 47 may be configured to include track sections thatloop into each growth environment 20 a-20 g. A control system can causetransfer conveyance mechanism 47 to route carriages 1202 to select growlines 202 within a select growth environment. As discussed above, eachgrowth environment 20 a-20 g includes a tower injection interface 38 anda tower extraction interface 39. As FIG. 27 illustrates, injection andextraction interfaces 38 and 39 are configured on the sides of growthenvironments 20 a-g that face central processing system 30. Thisconfiguration allows for reductions to the overall size of the cleanroom space required outside of the growth environments 20 a-g forcentral processing system 30 and the conveyance systems that transfergrow towers to and from it.

FIG. 27 also illustrates that the system 10 may also include a secondautomated pickup station 43 b. As discussed below, grow towers 50 may beinserted back into a select grow environment 20 a-g as so-called“cut-agains” after an initial processing by harvester station 32. Thegrow tower 50 may be horizontally conveyed to automated pickup station43. In an alternative embodiment, however, a second automated pickupstation 43 b located more proximally to harvester station 32 may pick upa “cut-again” grow tower 50 and load it onto a carriage 1202 of transferconveyance mechanism 47.

Irrigation & Aqueous Nutrient Supply

FIG. 8 illustrates how an irrigation line 802 may be attached to growline 202 to supply an aqueous nutrient solution to crops disposed ingrow towers 50 as they translate through the vertical tower conveyancesystem 200. Irrigation line 802, in one implementation, is a pressurizedline with spaced-apart holes or apertures disposed at the expectedlocations of the towers 50 as they advance along grow line 202 with eachmovement cycle. For example, the irrigation line 802 may be a PVC pipehaving an inner diameter of 1.5 inches and holes having diameters of0.125 inches. The irrigation line 802 may be approximately 40 meters inlength spanning the entire length of a grow line 202. To ensure adequatepressure across the entire line, irrigation line 802 may be broken intoshorter sections, each connected to a manifold, so that pressure drop isreduced.

As FIG. 8 shows, a funnel structure 902 collects aqueous nutrientsolution from irrigation line 802 and distributes the aqueous nutrientsolution to the cavity(ies) 54 a, 54 b of the grow tower 50 as discussedin more detail below. FIGS. 9 and 11A illustrate that the funnelstructure 902 may be integrated into hook 52. For example, the funnelstructure 902 may include a collector 910, first and second passageways912 and first and second slots 920. As FIG. 9 illustrates, thegroove-engaging member 58 of the hook may disposed at a centerline ofthe overall hook structure. The funnel structure 902 may include flangesections 906 extending downwardly opposite the collector 910 and onopposing sides of the centerline. The outlets of the first and secondpassageways are oriented substantially adjacent to and at opposing sidesof the flange sections 906, as shown. Flange sections 906 register withcentral wall 56 of grow tower 50 to center the hook 52 and providesadditional sites to adhere or otherwise attach hook 52 to grow tower 50.In other words, when hook 52 is inserted into the top of grow tower 50,central wall 56 is disposed between flange sections 906. In theimplementation shown, collector 910 extends laterally from the main body53 of hook 52.

As FIG. 11B shows, funnel structure 902 includes a collector 910 thatcollects nutrient fluid and distributes the fluid evenly to the innercavities 54 a and 54 b of tower through passageways 912. Passageways 912are configured to distribute aqueous nutrient solution near the centralwall 56 and to the center back of each cavity 54 a, 54 b over the endsof the plug holders 158 and where the roots of a planted crop areexpected. As FIG. 11C illustrates, in one implementation, the funnelstructure 902 includes slots 920 that promote the even distribution ofnutrient fluid to both passageways 912. For nutrient fluid to reachpassageways 912, it must flow through one of the slots 920. Each slot920 may have a V-like configuration where the width of the slot openingincreases as it extends from the substantially flat bottom surface 922of collector 910. For example, each slot 920 may have a width of 1millimeter at the bottom surface 922. The width of slot 920 may increaseto 5 millimeters over a height of 25 millimeters. The configuration ofthe slots 920 causes nutrient fluid supplied at a sufficient flow rateby irrigation line 802 to accumulate in collector 910, as opposed toflowing directly to a particular passageway 912, and flow through slots920 to promote even distribution of nutrient fluid to both passageways912.

In operation, irrigation line 802 provides aqueous nutrient solution tofunnel structure 902 that even distributes the water to respectivecavities 54 a, 54 b of grow tower 50. The aqueous nutrient solutionsupplied from the funnel structure 902 irrigates crops contained inrespective plug containers 158 as it trickles down. In oneimplementation, a gutter disposed under each grow line 202 collectsexcess water from the grow towers 50 for recycling.

Other implementations are possible. For example, the funnel structuremay be configured with two separate collectors that operate separatelyto distribute aqueous nutrient solution to a corresponding cavity 54 a,54 b of a grow tower 50. In such a configuration, the irrigation supplyline can be configured with one hole for each collector. In otherimplementations, the towers may only include a single cavity and includeplug containers only on a single face 101 of the towers. Such aconfiguration still calls for a use of a funnel structure that directsaqueous nutrient solution to a desired portion of the tower cavity, butobviates the need for separate collectors or other structuresfacilitating even distribution.

Automated Pickup & Laydown Stations

As discussed above, the stations of central processing system 30 operateon grow towers 50 in a horizontal orientation, while the vertical towerconveyance system 200 conveys grow towers in the growth environment 20in a vertical orientation. In one implementation, an automated pickupstation 43, and associated control logic, may be operative to releasablygrasp a horizontal grow tower from a loading location, rotate the towerto a vertical orientation and attach the tower to a carriage of transferconveyance mechanism 47 for insertion into a selected grow line 202 of agrowth environment 20. On the other end of central processing system 30,automated laydown station 41, and associated control logic, may beoperative to releasably grasp and move a vertically-oriented grow tower50 from a buffer location, rotate the grow tower 50 to a horizontalorientation and place it on a conveyance system for processing by one ormore stations of central processing system 30. For example, automatedlaydown station 41 may place grow towers 50 on a conveyance system forloading into harvester station 32. The automated laydown station 41 andpickup station 43 may each comprise a six-degrees of freedom (six axes)robotic arm, such as a FANUC robot. The stations 41 and 43 may alsoinclude end effectors for releasably grasping grow towers 50 at opposingends. Automated pick up and laydown station 42 may be configured toperform both functions implemented by stations 41 and 43.

FIG. 14 illustrates an automated laydown station 41 according to oneimplementation of the invention. As shown, automated laydown station 41includes robot 1402 and end effector 1450. As discussed above, transferconveyance mechanism 47, which may be a power and free conveyor,delivers grow towers 50 from growth environment 20. In oneimplementation, the track system 1406 of transfer conveyance mechanism47 extends through a vertical slot 1408 of tower extraction interface 39in growth environment 20, allowing mechanism 45 to convey grow towers 50attached to carriages 1202 outside of growth environment 20 and towardspick location 1404. Transfer conveyance mechanism 47 may use acontrolled stop blade to stop the carriage 1202 at the pick location1404. The transfer conveyance mechanism 47 may include an anti-roll backmechanism, bounding the carriage 1202 between the stop blade and theanti-roll back mechanism.

As FIG. 12 illustrates, receiver 1204 may be attached to a swivelmechanism 1210 allowing rotation of grow towers 50 when attached tocarriages 1202 for closer buffering in unload transfer conveyancemechanism 45 and/or to facilitate the correct orientation for loading orunloading grow towers 50. In some implementations, for the laydownlocation and pick location 1404, grow towers 50 may be oriented suchthat hook 52 faces away from the automated laydown and pickup stations41, 43 for ease of transferring towers on/off the swiveled carriagereceiver 1204. Hook 52 may rest in a groove in the receiver 1204 ofcarriage 1202. Receiver 1204 may also have a latch 1206 which closesdown on either side of the grow tower 50 to prevent a grow tower 50 fromsliding off during acceleration or deceleration associated with transferconveyance. In other implementations, however, the return transfermechanism 220 may be configured to obviate the need for swivel mechanism1210, given that the transfer of grow towers into and from a carriage1202 can occur on the same side for all operations.

FIG. 16 illustrates an end effector 1450, according to oneimplementation of the invention, that provides a pneumatic grippingsolution for releasably grasping a grow tower 50 at opposing ends. Endeffector 1450 may include a beam 1602 and a mounting plate 1610 forattachment to a robot, such as robotic arm 1402. A top gripper assembly1604 and a bottom gripper assembly 1606 are attached to opposite ends ofbeam 1602. End effector 1450 may also include support arms 1608 tosupport a grow tower 50 when held in a horizontal orientation. Forexample, support arms 1608 extending from a central section of beam 1602mitigate tower deflection. Support arms 1608 may be spaced ˜1.6 metersfrom either gripper assembly 1604, 1606, and may be nominally 30 mmoffset from a tower face, allowing 30 mm of tower deflection before thesupport arms 1608 catch the tower.

Bottom gripper assembly 1606, as shown in FIGS. 17A and 17B, may includeplates 1702 extending perpendicularly from an end of beam 1602 and eachhaving a cut-out section 1704 defining arms 1708 a and 1708 b. Apneumatic cylinder mechanism 1706, such as a guided pneumatic cylindersold by SMC Pneumatics under the designation MGPM40-40Z, attaches toarms 1708 a of plates 1702. Arms 1708 b may include projections 1712that engage groove 58 b of grow tower 50 when grasped therein to locatethe grow tower 50 in the gripper assembly 1606 and/or to preventslippage. The gripper assembly 1606, in the implementation shown,operates like a lobster claw—i.e., one side of the gripper (thepneumatic cylinder mechanism 1706) moves, while the other side (arms1708 b) remain static. On the static side of the gripper assembly 1606,the pneumatic cylinder mechanism 1706 drives the grow tower 50 into thearms 1708, registering the tower 50 with projections 1712. Frictionbetween a grow tower 50 and arms 1708 b and pneumatic cylinder mechanism1706 holds the tower 50 in place during operation of an automatedlaydown or pick up station 41, 43. To grasp a grow tower 50, thepneumatic cylinder mechanism 1706 may extend. In such an implementation,pneumatic cylinder mechanism 1706 is retracted to a release positionduring a transfer operation involving the grow towers 50. In oneimplementation, the solenoid of pneumatic cylinder mechanism 1706 iscenter-closed in that, whether extended or retracted, the valve lockseven if air pressure is lost. In such an implementation, loss of airpressure will not cause a grow tower 50 to fall out of end effector 1450while the pneumatic cylinder mechanism 1706 is extended.

Top gripper assembly 1604, in one implementation, is essentially amirror image of bottom gripper assembly 1606, as it includes the samecomponents and operates in the same manner described above. Catch plate1718, in one implementation, may attach only to bottom gripper assembly1606. Catch plate 1718 may act as a safety catch in case the gripperassemblies fail or the grow tower 50 slips. Other implementations arepossible. For example, the gripper assemblies may be parallel gripperassemblies where both opposing arms of each gripper move when actuatedto grasp a grow tower 50.

Robot 1402 may be a 6-axis robotic arm including a base, a lower armattached to the base, an upper arm attached to the lower arm, and awrist mechanism disposed between the end of the upper arm and an endeffector 1450. For example, robot 1402 may 1) rotate about Its base; 2)rotate a lower arm to extend forward and backward; 3) rotate an upperarm, Relative to the lower arm, upward and downward; 4) rotate the upperarm and attached wrist Mechanism in a circular motion; 5) tilt a wristmechanism attached to the end of the upper Arm up and down; and/or 6)rotate the wrist mechanism clockwise or counter-clockwise. However,modifications to end effector 1450 (and/or other elements, such asconveyance mechanisms and the like) may permit different types of robotsand mechanisms, as well as use of robots with fewer axes of movement. AsFIG. 18 illustrates, robot 1402 may be floor mounted and installed on apedestal. Inputs to the robot 1402 may include power, a data connectionto a control system, and an air line connecting the pneumatic cylindermechanism 1706 to a pressurized air supply. On pneumatic cylindermechanism 1706, sensors may be used to detect when the cylinder is inits open state or its closed state. The control system may execute oneor more programs or sub-routines to control operation of the robot 1402to effect conveyance of grow towers 50 from growth environment 20 tocentral processing system 20.

When a grow tower 50 accelerates/decelerates in unload transferconveyance mechanism 45, the grow tower 50 may swing slightly. FIGS. 18and 19 illustrate a tower constraining mechanism 1902 to stop possibleswinging, and to accurately locate, a grow tower 50 during a laydownoperation of automated laydown station 41. In the implementation shown,mechanism 1902 is a floor-mounted unit that includes a guided pneumaticcylinder 1904 and a bracket assembly including a guide plate 1906 thatguides a tower 50 and a bracket arm 1908 that catches the bottom of thegrow tower 50, holding it at a slight angle to better enableregistration of the grow tower 50 to the bottom gripper assembly 1606. Acontrol system may control operation of mechanism 1902 to engage thebottom of a grow tower 50, thereby holding it in place for gripperassembly 1606.

The end state of the laydown operation is to have a grow tower 50 layingon the projections 2004 of the harvester infeed conveyor 1420, ascentered as possible. In one implementation, a grow tower 50 is orientedsuch that hook 52 points towards harvester station 32 and, inimplementations having hinged side walls, and hinge side down. Thefollowing summarizes the decisional steps that a controller for robot1402 may execute during a laydown operation, according to one possibleimplementation of the invention.

Laydown Procedure Description

The Main program for the robot controller may work as follows:

-   -   A control system associated with central processing system 30        may activate the robot controller's Main program.    -   Within the Main program, the robot controller may check if robot        1402 is in its home position.    -   If robot 1402 is not in its home position, it enters its Home        program to move to the home position.    -   The Main program then calls the reset I/O program to reset all        the I/O parameters on robot 1402 to default values.    -   Next, the Main program runs the handshake program with the        central processing controller to make sure a grow tower 50 is        present at the pickup location 1404 and ready to be picked up.    -   The Main program may run an enter zone program to indicate it is        about to enter the transfer conveyance zone.    -   The Main program may run a Pick Tower program to grasp a grow        tower 50 and lift it off of carriage 1202.    -   The Main program may then call the exit zone program to indicate        it has left the transfer conveyance zone.    -   Next the Main program runs the handshake program with the        central processing controller to check whether the harvester        infeed conveyor 1420 is clear and in position to receive a grow        tower 50.    -   The Main program may then run the enter zone program to indicate        it is about to enter the harvester infeed conveyor zone.    -   The Main program runs a Place Tower program to move and place        the picked tower onto the infeed conveyor 1420.    -   The Main program then calls an exit zone program to indicate it        has left the harvester infeed conveyor zone.    -   The Home program may then run to return robot 1402 to its home        position.    -   Lastly, the Main program may run the handshake program with the        central processing controller to indicate robot 1402 has        returned to its home position and is ready to pick the next grow        tower 50.

The Pick Tower program may work as follows:

-   -   Robot 1402 checks to make sure the grippers 1604, 1606 are in        the open position. If the grippers are not open, robot 1402 will        throw an alarm.    -   Robot 1402 may then begin to move straight ahead which will push        the end effector 1450 into the tower face so that the grow tower        is fully seated against the back wall of the grippers 1604,        1606.    -   Robot 1402 may then move sideways to push the rigid fingers 1712        against the tower walls to engage groove 58 b.    -   Robot 1402 may activate robot outputs to close the grippers        1604, 1606.    -   Robot 1402 may wait until sensors indicate that the grippers        1604, 1606 are closed. If robot 1402 waits too long, robot 1402        may throw an alarm.    -   Once grip is confirmed, robot 1402 may then move vertically to        lift grow tower 50 off of the receiver 1204.    -   Next, robot 1402 may then pull back away from pick location        1404.

The Place Tower program may work as follows:

-   -   Robot 1402 may move through two waypoints that act as        intermediary points to properly align grow tower 50 during the        motion.    -   Robot 1402 continues on to position end effector 1450 and grow        tower 50 just above the center of the harvester in-feed conveyor        1450, such that the tower is in the correct orientation (e.g.,        hinge down on the rigid fingers, hook 52 towards harvester        station 32).    -   Once the conveyor position is confirmed, robot 1402 may then        activate the outputs to open grippers 1604, 1606 so that grow        tower 50 is just resting on the rigid fingers 1712 and support        arms 1608.    -   Robot 1402 may wait until the sensors indicate that grippers        1604, 1606 have opened. If robot 1402 waits too long, robot 1402        may throw an alarm.    -   After grippers 1604, 1606 are released, robot 1402 may then move        vertically down. On the way down the projections 2004 of        harvester infeed conveyor 1420 take the weight of grow tower 50        and the rigid fingers 1712 and support arms 1608 of end effector        1450 end up under grow tower and not in contact.    -   Lastly, robot 1402 may then pull end effector 1450 towards robot        1402, away from harvester infeed conveyor 1420, and slides rigid        fingers 1712 of end effector 1450 out from under grow tower 50.

FIGS. 15A and 15B illustrate an automated pickup station 43 according toone implementation of the invention. As shown, automated pickup station43 includes robot 1502 and pickup conveyor 1504. Similar to automatedlaydown station 41, robot 1502 includes end effector 1550 for releasablygrasping grow towers 50. In one implementation, end effector 1550 issubstantially the same as end effector 1450 attached to robot 1402 ofautomated laydown station 41. In one implementation, end effector 1550may omit support arms 1608. As described herein, robot 1502, using endeffector 1550, may grasp a grow tower 50 resting on pickup conveyor1504, rotate the grow tower 50 to a vertical orientation and attach thegrow tower 50 to a carriage 1202 of transfer conveyance mechanism 47. Asdiscussed above, loading transfer conveyance mechanism 47, which mayinclude be a power and free conveyor, delivers grow towers 50 to growthenvironment 20. In one implementation, the track system 1522 of transferconveyance mechanism 47 extends through a vertical slot of towerinjection interface 38 in growth environment 20, allowing mechanism 47to convey grow towers 50 attached to carriages 1202 into growthenvironment 20 from stop location 1520. Transfer conveyance mechanism 47may use a controlled stop blade to stop the carriage 1202 at the stoplocation 1520. Transfer conveyance mechanism 47 may include an anti-rollback mechanism, bounding the carriage 1202 between the stop blade andthe anti-roll back mechanism.

The following summarizes the decisional steps that a controller forrobot 1502 may execute during a pickup operation, according to onepossible implementation of the invention.

Pickup Procedure Description

-   -   The Main program for the robot controller may work as follows        for robot 1502:    -   The central processing controller may activate the Main program.    -   Within the Main program, robot 1502 controller will check if        robot 1502 is in its home position.    -   If robot 1502 is not in its home position, robot 1502 will enter        its home program to move to the home position of the robot 1502.    -   The Main program may then call the reset IO program to reset I/O        values on robot 1502 to their default values.    -   Next, the Main program may run the handshake program with the        central processing controller to request a decision code        indicating which station (pickup conveyor 1504 or the        transplanter transfer conveyor 2111) has a grow tower 50 ready        for pickup.    -   The Main program may run the enter zone program to indicate it        is about to enter the pickup location based on the decision code        from above.    -   The Main program may then run the Pick Tower program to grab a        tower and lift it from the specified conveyor based on the        decision code from above.    -   The Main program may then call the exit zone program to indicate        it has left the pickup location based on the decision code from        above.    -   Next the Main program may run the handshake program with the        central processing controller to check whether loading transfer        conveyance mechanism 47 has a carriage 1202 in place and is        ready to receive a grow tower 50.    -   The Main program may then run the enter zone program to indicate        it is about to enter the transfer conveyance zone.    -   The Main program may run the Place Tower program to move and        place the picked grow tower onto receiver 1204 of carriage 1202.    -   The Main program may then call the exit zone program to indicate        it has left the transfer conveyance zone.    -   Robot 1502 then run the go to Home program to return robot 1502        to its home position.    -   Lastly, the Main program may run the handshake program with the        central processing controller to indicate robot 1502 has        returned to its home position and is ready to pick up the next        grow tower 50.

The Pick Tower program may work as follows:

-   -   Robot 1502 may check to make sure the grippers are in the open        position. If they are not open, robot 1502 will throw an alarm.    -   If the decision location resolves to the transplanter transfer        conveyor 2111, robot 1502 will move vertically to align with the        grow tower 50 on the transplanter transfer conveyor 2111.    -   Robot 1502 may then begin to move straight ahead to push end        effector 1550 into the tower face so that the grow tower 50 is        fully seated against the back wall of the grippers.    -   Robot 1502 moves upwards to lift grow tower 50 to rest the tower        on the rigid fingers of the grippers.    -   Robot 1502 may then activate robot 1502 outputs to close the        grippers.    -   Robot 1502 may wait until the sensors indicate that the grippers        are closed. If robot 1502 waits too long, robot 1502 will throw        an alarm.    -   Once grip is confirmed, robot 1502 moves vertically and pulls        back away from the pickup conveyor 1504 or the transplanter        transfer conveyor 2111.        The Place Tower program may work as follows:    -   Robot 1502 may move through two waypoints that act as        intermediary points to properly align grow tower 50 during the        motion.    -   Robot 1502 continues on to position end effector 1550 and grow        tower 50 in line with receiver 1204 of carriage 1202.    -   Robot 1502 may then move forward to point 1520 which will        position the tower hook 52 above the channel in receiver 1204.    -   Robot 1502 may then move down which will position the tower hook        52 to be slightly above (e.g., ˜10 millimeters) above the        channel of receiver 1204.    -   Robot 1502 may activate the outputs to open the grippers so that        the hook 52 of tower 50 falls into the channel of receiver 1204.    -   Robot 1502 may wait until the sensors indicate that the grippers        have opened. If robot 1502 waits too long, robot 1502 will throw        an alarm.    -   Once the grippers are released, robot 1502 may move straight        back away from the tower.

Central Processing System

As discussed above, central processing system 30 may include harvesterstation 32, washing station 34 and transplanter station 36. Centralprocessing system 30 may also include one or more conveyors to transfertowers to or from a given station. For example, central processingsystem 30 may include harvester outfeed conveyor 2102, washer infeedconveyor 2104, washer outfeed conveyor 2106, transplanter infeedconveyor 2108, and transplanter outfeed conveyor 2110. These conveyorscan be belt or roller conveyors adapted to convey grow towers 50 layinghorizontally thereon. As described herein, central processing system 30may also include one or more sensors for identifying grow towers 50 andone or more controllers for coordinating and controlling the operationof various stations and conveyors.

FIG. 21 illustrates an example processing pathway for central processingsystem 30. As discussed above, a robotic laydown station 41 may lower agrow tower 50 with mature crops onto a harvester infeed conveyor 1420,which conveys the grow tower 50 to harvester station 32. FIG. 20illustrates a harvester infeed conveyor 1420 according to oneimplementation of the invention. Harvester infeed conveyor 1420 may be abelt conveyor having a belt 2002 including projections 2004 extendingoutwardly from belt 2002. Projections 2004 provide for a gap betweenbelt 2002 and crops extending from grow tower 50, helping to avoid orreduce damage to the crops. In one implementation, the size theprojections 2004 can be varied cyclically at lengths of grow tower 50.For example, projection 2004 a may be configured to engage the end ofgrow tower 50; top projection 2004 d may engage the opposite end of growtower 50; and middle projections 2004 b, c may be positioned to contactgrow tower 50 at a lateral face where the length of projections 2004 b,c are lower and engage grow tower 50 when the tower deflects beyond athreshold amount. The length of belt 2002, as shown in FIG. 20 can beconfigured to provide for two movement cycles for a grow tower 50 foreach full travel cycle of the belt 2002. In other implementations,however, all projections 2004 are uniform in length.

As FIG. 21 shows, harvester outfeed conveyor 2102 conveys grow towers 50that are processed from harvester station 32. In the implementationshown, central processing system 30 is configured to handle two types ofgrow towers: “cut-again” and “final cut.” As used herein, a “cut-again”tower refers to a grow tower 50 that has been processed by harvesterstation 32 (i.e., the crops have been harvested from the plants growingin the grow tower 50, but the root structure of the plant(s) remain inplace) and is to be re-inserted in growth environment 20 for crops togrow again. As used herein, a “final cut” tower refers to a grow tower50 where the crops are harvested and where the grow tower 50 is to becleared of root structure and growth medium and re-planted. Cut-againand final cut grow towers 50 may take different processing paths throughcentral processing system 30. To facilitate routing of grow towers 50,central processing system 30 includes sensors (e.g., RFID, barcode, orinfrared) at various locations to track grow towers 50. Control logicimplemented by a controller of central processing system 30 trackswhether a given grow tower 50 is a cut-again or final cut grow tower andcauses the various conveyors to route such grow towers accordingly. Forexample, sensors may be located at pick position 1404 and/or harvesterinfeed conveyor 1420, as well as at other locations. The variousconveyors described herein can be controlled to route identified growtowers 50 along different processing paths of central processing system30. As shown in FIG. 21 , a cut-again conveyor 2112 transports acut-again grow tower 50 toward the work envelope of automated pickupstation 43 for insertion into grow environment 20. Cut-again conveyor2112 may consist of either a single accumulating conveyor or a series ofconveyors. Cut-again conveyor 2112 may convey a grow tower 50 to pickupconveyor 1504. In one implementation, pickup conveyor 1504 is configuredto accommodate end effector 1450 of automated pickup station 43 thatreaches under grow tower 50. Methods of accommodating the end effector1450 include either using a conveyor section that is shorter than growtower 50 or using a conveyor angled at both ends as shown in FIG. 22 .

Final cut grow towers 50, on the other hand, travel through harvesterstation 32, washing station 34 and transplanter 36 before reenteringgrowth environment 20. With reference to FIG. 21 , a harvested growtower 50 may be transferred from harvester outfeed conveyor 2102 to awasher transfer conveyor 2103. The washer transfer conveyor 2103 movesthe grow tower onto washer infeed conveyor 2104, which feeds grow tower50 to washing station 34. In one implementation, pneumatic slides maypush a grow tower 50 from harvester outfeed conveyor 2102 to washertransfer conveyor 2103. Washer transfer conveyor 2103 may be athree-strand conveyor that transfers the tow to washer infeed conveyor2104. Additional pusher cylinders may push the grow tower 50 off washertransfer conveyor 2103 and onto washer infeed conveyor 2104. A growtower 50 exits washing station 34 on washer outfeed conveyor 2106 and,by way of a push mechanism, is transferred to transplanter infeedconveyor 2108. The cleaned grow tower 50 is then processed intransplanter station 36, which inserts seedlings into grow sites 53 ofthe grow tower. Transplanter outfeed conveyor 2110 transfers the growtower 50 to final transfer conveyor 2111, which conveys the grow tower50 to the work envelope of automated pickup station 43.

In the implementation shown in FIG. 23A, harvester station 34 comprisescrop harvester machine 2302 and bin conveyor 2304. Harvester machine2302 may include a rigid frame to which various components, such ascutters and feed assemblies, are mounted. Harvester machine 2302, in oneimplementation, includes its own feeder mechanism that engages a growtower 50 and feeds it through the machine. In one implementation,harvester machine 2302 engages a grow tower on the faces that do notinclude grow sites 53 and may employ a mechanism that registers withgrooves 58 a, 58 b to accurately locate the grow tower and grow sites 53relative to harvesting blades or other actuators. In one implementation,harvester machine 2302 includes a first set of rotating blades that areoriented near a first face 101 of a grow tower 50 and a second set ofrotating blades on an opposing face 101 of the grow tower 50. As thegrow tower 50 is fed through the harvester machine 2302, crop extendingfrom the grow sites 53 is cut or otherwise removed, where it falls intoa bin placed under harvester machine 2302 by bin conveyor 2304.Harvester machine 2302 may include a grouping mechanism, such as aphysical or air grouper, to group the crops at a grow site 53 away fromthe face plates 101 of the grow towers 50 in order to facilitate theharvesting process. Bin conveyor 2304 may be a u-shaped conveyor thattransports empty bins the harvester station 34 and filled bins fromharvester station 32. In one implementation, a bin can be sized to carryat least one load of crop harvested from a single grow tower 50. In suchan implementation, a new bin is moved in place for each grow tower thatis harvested. In one implementation, grow towers 50 enter the harvestermachine 2302 full of mature plants and leave the harvester machine 2302with remaining stalks and soil plugs to be sent to the next processingstation.

FIG. 23B is a top view of an example harvester machine 2302. Circularblades 2306 extending from a rotary drive system 2308 harvest plants onopposing faces 101 a of grow towers 50. In one implementation, rotarydrive system 2308 is mounted to a linear drive system 2310 to move thecircular blades 2306 closer to and farther away from the opposing faces101 a of the grow towers 50 to optimize cut height for different typesof plants. In one implementation, each rotary drive system 2308 has anupper circular blade and a lower circular blade (and associated motors)that intersect at the central axis of the grow sites of the grow towers50. Harvester machine 2302 may also include an alignment track 2320 thatincludes a set of rollers that engage groove 58 of the grow tower 50 asit is fed through the machine. Harvester machine 2302 may also include atower drive system that feeds grow towers through the machine at aconstant rate. In one implementation, the tower drive system includes atwo drive wheel and motor assemblies located at opposite ends ofharvester machine 2302. Each drive wheel and motor assembly may includea friction drive roller on the bottom and a pneumatically actuatedalignment wheel on the top. As FIG. 23C illustrates, harvester machine2302 may also include a gathering chute 2330 that collects harvestedcrops cut by blades 2306 as it falls and guides it into bins locatedunder the machine 2302.

Washing station 34 may employ a variety of mechanisms to clean cropdebris (such as roots and base or stem structures) from grow towers 50.To clean a grow tower 50, washing station 34 may employ pressurizedwater systems, pressurized air systems, mechanical means (such asscrubbers, scrub wheels, scrapers, etc.), or any combination of theforegoing systems. In implementations that use hinged grow towers (suchas those discussed above), the washing station 34 may include aplurality of substations including a substation to open the front faces101 of grow towers 50 prior to one or more cleaning operations, and asecond substation to close the front faces 101 of grow towers after oneor more cleaning operations.

Transplanter station 36, in one implementation, includes an automatedmechanism to inject seedlings into grow sites 53 of grow towers 50. Inone implementation, the transplanter station 36 receives plug trayscontaining seedlings to be transplanted into the grow sites 53. In oneimplementation, transplanter station 36 includes a robotic arm and anend effector that includes one or more gripper or picking heads thatgrasps root-bound plugs from a plug tray and inserts them into growsites 53 of grow tower 53. For implementations where grow sites 53extend along a single face of a grow tower, the grow tower may beoriented such that the single face faces upwardly. For implementationswhere grow sites 53 extend along opposing faces of a grow tower 50, thegrow tower 50 may be oriented such that the opposing faces having thegrow sites face laterally. FIGS. 24A and 24B illustrate an exampletransplanter station. Transplanter station 36 may include a plug trayconveyor 2430 that positions plug trays 2432 in the working envelope ofa robotic arm 2410. Transplanter station 36 may also include a feedmechanism that loads a grow tower 50 into place for transplanting.Transplanter station 36 may include one or more robotic arms 2410 (suchas a six-axis robotic arm), each having an end effector 2402 that isadapted to grasp a root-bound plug from a plug tray and inject the rootbound plug into a grow site 53 of a grow tower. FIG. 24A illustrates anexample end effector 2402 that includes a base 2404 and multiple pickingheads 2406 extending from the base 2404. The picking heads 2406 are eachpivotable from a first position to a second position. In a firstposition (top illustration of FIG. 24A), a picking head 2406 extendsperpendicularly relative to the base. In the second position shown inFIG. 24A, each picking head 2406 extends at a 45-degree angle relativeto the base 2404. The 45-degree angle may be useful for injecting plugsinto the plug containers 158 of grow towers that, as discussed above,extend at a 45-degree angle. A pneumatic system may control the pivotingof the picking heads between the first position and the second position.In operation, the picking heads 2406 may be in the first position whenpicking up root-bound plugs from a plug tray, and then may be moved tothe second position prior to insertion of the plugs into plug containers158. In such an insertion operation, the robotic arm 2410 can beprogrammed to insert in a direction of motion parallel with theorientation of the plug container 158. Using the end effectorillustrated in FIG. 24A, multiple plug containers 158 may be filled in asingle operation. In addition, the robotic arm 2410 may be configured toperform the same operation at other regions on one or both sides of agrow tower 50. As FIG. 24B shows, in one implementation, several roboticassemblies, each having an end effector 2402 are used to lowerprocessing time. After all grow sites 53 are filled, the grow tower 50is ultimately conveyed to automated pickup station 43, as describedherein.

One or more of the controllers discussed above, such as the one or morecontrollers for central processing system 30, may be implemented asfollows. FIG. 25 illustrates an example of a computer system 800 thatmay be used to execute program code stored in a non-transitory computerreadable medium (e.g., memory) in accordance with embodiments of thedisclosure. The computer system includes an input/output subsystem 802,which may be used to interface with human users or other computersystems depending upon the application. The I/O subsystem 802 mayinclude, e.g., a keyboard, mouse, graphical user interface, touchscreen,or other interfaces for input, and, e.g., a LED or other flat screendisplay, or other interfaces for output, including application programinterfaces (APIs). Other elements of embodiments of the disclosure, suchas the controller, may be implemented with a computer system like thatof computer system 800.

Program code may be stored in non-transitory media such as persistentstorage in secondary memory 810 or main memory 808 or both. Main memory808 may include volatile memory such as random-access memory (RAM) ornon-volatile memory such as read only memory (ROM), as well as differentlevels of cache memory for faster access to instructions and data.Secondary memory may include persistent storage such as solid-statedrives, hard disk drives or optical disks. One or more processors 804reads program code from one or more non-transitory media and executesthe code to enable the computer system to accomplish the methodsperformed by the embodiments herein. Those skilled in the art willunderstand that the processor(s) may ingest source code, and interpretor compile the source code into machine code that is understandable atthe hardware gate level of the processor(s) 804. The processor(s) 804may include graphics processing units (GPUs) for handlingcomputationally intensive tasks.

The processor(s) 804 may communicate with external networks via one ormore communications interfaces 807, such as a network interface card,WiFi transceiver, etc. A bus 805 communicatively couples the I/Osubsystem 802, the processor(s) 804, peripheral devices 806,communications interfaces 807, memory 808, and persistent storage 810.Embodiments of the disclosure are not limited to this representativearchitecture. Alternative embodiments may employ different arrangementsand types of components, e.g., separate buses for input-outputcomponents and memory subsystems.

Those skilled in the art will understand that some or all of theelements of embodiments of the disclosure, and their accompanyingoperations, may be implemented wholly or partially by one or morecomputer systems including one or more processors and one or more memorysystems like those of computer system 800. In particular, the elementsof automated systems or devices described herein may becomputer-implemented. Some elements and functionality may be implementedlocally and others may be implemented in a distributed fashion over anetwork through different servers, e.g., in client-server fashion, forexample.

Facility Layout & Arrangement

FIGS. 28 and 29 are a functional block diagrams illustrating an examplecontrolled-environment agriculture production facility 2800. In someimplementations, the layout illustrated in FIGS. 28 and 29 incorporatethe configuration of the growth environments and central processingillustrated in FIG. 27 , adding to it the selection and arrangement ofother spaces and functionality of the facility 2800. In otherimplementations, the configuration illustrate in FIG. 1A can beincorporated. As FIG. 28 illustrates, production facility 2800 includesgrowth environment 20, central processing system 30, nutrient andthermal corridor 2820, propagation space 2802, pre-harvest processingspace 2804, and post-harvest processing space 2806. Production facility2800 also includes seeding space 2808, germination space 2803, andmaterials or product supply handling space 2822. One or more space orarea components of production facility 2800 may be housed within awarehouse building or any other suitable building structure.

As discussed above, growth environment 20 may be asubstantially-encapsulated space to facilitate control of one or moreenvironmental conditions to which crops are exposed and to reduce riskof potential contaminants and pests. Growth environment 20 may comprisean array of multiple growth environments 20 a-f, as illustrated in FIG.27 and as discussed above. Each of the growth environments 20 a-f may beseparately controlled to support optimized growing for a variety ofdifferent crop types. As discussed above, the growth environments 20 a-fmay each contain one or more grow lines 202 that have a substantiallyu-shaped travel path including a first path section 202 a and a secondreturn path section 202 b (see above). In the implementation shown,transfer conveyance mechanism 47 may be configured to include tracksections that loop into each growth environment 20 a-20 f A controlsystem can cause transfer conveyance mechanism 47 to route carriages1202 to select grow lines 202 within a select growth environment 20 a-20f. The control system may also cause transfer conveyance mechanism 47 toroute carriages 1202 to a select pre-harvest buffer 2190, 2192 withinpre-harvesting processing space 2804.

In the implementation of central processing system 30 shown in FIG. 28 ,the processing path associated with harvesting station 32 isperpendicular to the processing paths associated with washing station 34and transplanter station 36. Pre-harvest processing space 2804 maycontain harvester station 32 and one or more pre-harvesting buffers2190, 2192, as discussed above. Automated laydown station 41 may engagea grow tower 50 from one of buffers 2190, 2192, rotate the grow tower 50to a horizontal orientation and place it on a conveyance mechanism thatfeeds the grow tower 50 through harvester station 32. For so-called“cut-again” towers, automated pick up station 43 b may place theharvested grow tower 50 back onto transfer conveyance mechanism 47,which routes the tower to a select growth environment 20 a-f. Otherwise,automated pickup station 43 b may rotate the grow tower 90 degrees andplace it horizontally onto a conveyance mechanism that feeds the growtower to washing station 34. A washed grow tower 50 may be buffered inbuffering mechanism 35 with other grow towers 50 and ultimately fed intotransplanter station 36. Automated pickup station 43 may engage a growtower 50 that has been transplanted and transfer it to transferconveyance mechanism 47, which routes the tower to a select growthenvironment 20 a-f.

Nutrient and thermal corridor 2820 contains one or more fluid tanks,nutrient supply and mixing equipment, fluid pumps, filtration equipment,sanitation equipment, manifolds, plumbing and related equipment toprovide aqueous nutrients to grow lines 202 within the growthenvironments 20 a-f. Nutrient and thermal corridor 2820 also includesequipment for controlling thermal conditions as well including, forexample, chillers and hydronic piping that run to air handling units andfluid coolers. In one implementation, modular aqueous nutrient supplysystems 2614 can supply aqueous nutrient solution to the grow lines 202within the growth environments 20 a-f. The plumbing (not shown)delivering nutrient solution from the aqueous nutrient supply system2614 can extend over growth environment 20 and/or grow lines 202.Furthermore, HVAC systems, such as chillers, air handlers and otherequipment bay be housed between sections of growth environment 20 a-fand/or placed on the top of the structure that contains each growthenvironment 20 a-f. Nutrient and thermal corridor 2820 isenvironmentally separated from growth environments 20 a-f, propagationspace 2802 and central processing system 30. Given that corridor 2820does not contain agricultural product, it may be subject to looserenvironmental controls (e.g., heat, humidity, insulation, cleanliness,etc.) than other spaces in facility 2800. For example, corridor 2820 maybe classified as a Group U (Utility and Miscellaneous) space pursuant toTitle 24 of the California Code of Regulations. As such, implementers ofthe facility 2800 can reduce costs by building to the lower requirementsof corridor 2820, while building to higher requirements in other spacesof facility 2800.

Propagation space 2802 includes equipment for growing young plants instacked horizontal beds (or plug trays) for later transplant into growtowers 50. Propagation space 2802 may include a rack system forvertically stacking the horizontal beds or plug trays. In oneimplementation, propagation space 2802 is a substantially encapsulatedgrowth environment that includes air handling, lighting, climatecontrol, irrigation and other equipment to grow plants from seed stageto transplant stage. The grow lights used in propagation space 2802 maybe air-cooled and located above each horizontal bed. In theimplementation shown in FIG. 28 , plug trays are inserted into andextracted from a single side 2818 (opposing corridor 2820) ofpropagation space 2802. In one implementation, the location ofpropagation space 2802 adjacent to the end of array of growthenvironments 20 a-f allows for a modular aqueous nutrient supply system2614 located in corridor 2820 to be the irrigation supply for the space2802.

Seeding area 2808 is a space including one or more stations andassociated equipment for filling plug trays with growth medium, seeds,and other nutrient or water solutions to meet the nutritionalrequirements for ideal growth per crop variety. In addition to a seedingline, the seeding space 2808 may also include media/soil storage,storage for seeds in a controlled temperature environment (e.g., arefrigerator) depending on requirements, and potentially media/soilmixing equipment. Seeding area 2808 may also include ventilationequipment. Germination space 2803 is an encapsulated space including oneor more tables where the newly seeded plug trays are contained duringplant germination. In the implementation shown in FIG. 28 , plug traysare inserted into and extracted from a single side 2809 (opposingcorridor 2820) of germination space 2803. After the germination phase,the plug trays may be transferred to propagation space 2802. In theimplementation shown, germination area 2803 and seeding area 2808 areadjacent to propagation space 2802.

In one embodiment, plants are initially grown in so-called plug trays,where each tray include multiple plugs that are ultimately transferredto transplanter station 36 when ready. As FIG. 28 demonstrates,propagation space 2802 is located adjacent to central processing systemand proximal to transplanter station 36. Such a configuration minimizesthe distance plug trays are required to travel from propagation space2802 to transplanter station 36. In one implementation, a conveyor maytransfer loaded plug trays from propagation area 2802 to transplanterstation 36.

The spaces associated with central processing system 30 may also bedivided into separate environments to achieve various objectives. Forexample, pre-harvesting space 2804 may be a cooled environment separatefrom the spaces that contain washing station 34 and transplanter station36. Post harvesting space 2806 may also be a separate space. In oneimplementation, pre-harvesting space 2804 includes environmentalcontrols for providing a cooled space to cool the crop in grow towers 50to a target temperature prior to harvesting and irrigation to supplywater or aqueous nutrient solution to grow towers 50 as they hang fromvertical buffers 2190, 2192. In one implementation, the irrigationsupply is a chilled water supply to further induce cooling of crop to atarget temperature prior to harvesting. For certain crops, such as leafygreens, the cooling of the crop facilitates cleaner harvestingoperations, as the crop is slightly more rigid, providing for cleanercuts by the blades of harvester station 32.

As discussed above, the vertical tower conveyance system 47 includes atrack system that routes carriages 1202 to various destinations alongthe system 10. As FIGS. 28 and 30 illustrate, the track system mayinclude a first pre-harvest (cut-again) vertical buffer 2190 and asecond pre-harvest (final-cut) vertical buffer 2192, both contained inpre-harvesting space 2804. As discussed above, central processing system30 may be configured to selectively process certain grow towers 50 forso-called cut-again processing. FIG. 28 illustrates that the system 10may also include a second automated pickup station 43 b. In particular,after processing by harvester station 32, automated pickup station 43 bmay pick up a grow tower 50 from the outfeed conveyor of harvesterstation 32 rotate the grow tower 50 to vertical and place it on acarriage 1202 of tower conveyance mechanism 47 for reinsertion into agrow line 202. A grow tower 50 that undergoes “final-cut” processing isrouted to washing station 34 and transplanter station 36 as describedherein. Pre-harvesting space 2804 may also include additional bufferlines for other purposes, such as a buffer line to place grow towerswith damaged or otherwise rejected crops.

Towers designated as “cut-agains” take less time to process than towers50 designated as final cuts, as cut-again towers need not pass throughcleaning station 34 and transplanter station 36. Pre-harvest buffers2190, 2192 provide a space to buffer grow towers 50 prior to initiatingharvester station 32 in order to ensure an adequate supply of growtowers 50 for efficient processing. A controller selectively routes growtowers 50, as appropriate, to either the cut-again buffer 2190 or finalcut buffer 2192. Automated laydown station 41 can selectively accessgrow towers 50 from either buffer 2190 or 2192 under control of acontrol system as may be required. The use of separate vertical towerbuffers allows the farm system 10 to alternate between cut-again andfinal-cut towers and maintain a consistent mix of final-cut andcut-again grow towers 50 for processing, despite such types of growtowers arriving in batches from growth environment. The use of separatebuffers also allows system 10 to accommodate for the different cycletimes of the cut-again and final-cut towers, increasing the total numberof towers than can be processed within a given time span and improvingthe average cycle time of overall tower processing. In oneimplementation, automated laydown station 41 can alternate 1:1 betweenfinal-cut and cut-again pre-harvest buffers 2190, 2192 provided thatboth tower types are available. In other implementations, however,differences in cycle times between such tower types may suggest a ratioof 2 cut-again towers for every 1 final-cut tower. Other implementationsare possible. For example, the system 10 may also include a verticalreject buffer (not shown) to provide a space to temporarily store growtowers that have failed a quality inspection. The reject buffer allows arejected tower to simply be routed out of the processing pathway andstored for later handling.

Post-harvest processing space 2806 may be an encapsulated environmentthat includes equipment for processing crops after they have beenharvested from grow towers 50 at harvester station 32. In someimplementations, post-harvest processing space 2806 is a substantiallyencapsulated space subject to controlled environmental conditions; forexample, post-harvesting space 2806 may be a cooled or refrigeratedenvironment, or a warmed environment to accommodate other types ofcrops. In some implementations, the equipment included in post-harvestprocessing space 2806 may include crop washing and drying equipment,product quality equipment, product cooling equipment, product packagingequipment, and food safety equipment. Other equipment may includeprocess isolation equipment for sanitation purposes. Post-harvestprocessing space 2806 is arranged adjacent to central processing system30 and proximal to harvester station 32 to minimize or reduce thedistance that harvested crop travels from harvester station 32. In oneimplementation, a bin conveyor can extend directly into post-harvestprocessing space 2806 to convey bins loaded with harvested crop into thespace. In one implementation, harvested product can be harvesteddirectly onto conveyance without bins, and transported to thepost-harvest processing space 2806. In addition, harvested product(whether in bins or conveyed directly on a conveyor) may also be subjectto cooling systems (such as vacuum cooling, a cooling tunnel, etc.) asit is conveyed to post-harvest processing space 2806. Similarly,facility 2800 may also include a cold storage space to provide acontrolled, refrigerated environment adapted for storing packaged cropsfor shipment depending on the specific crop storage environmentalrequirements. In some implementations, the equipment included in thecold storage space may include package palletizing equipment, caseerecting equipment, and other inventory storage equipment orinfrastructure. In the implementation shown, the cold storage space isadjacent to post-harvest processing space 2806.

Implementations of production facility 2800 are also arranged tooptimize efficiency. In some implementations, production facility 2800may be configured to reduce or minimize total product flow distance fromseed stage to post-harvest processing and cold storage. Minimizing orreducing this metric increases cost efficiencies by, for example,reducing the total length of conveyors used in the facility. The layoutof production facility 2800 may also be configured to reduce or minimizeother attributes, such as the percentage of unutilized space, thedistance of employee travel, the maximum distance between any twostations in the facility 2800, length of cabling, plumbing and/or HVACducting, and total wall length.

As FIG. 28 illustrates, total product flow from seed to packaging isboth direct and efficient, reducing operating time, operating cost andcapital expenditure. In particular, the product flow starts at seedstation 2808 where plug trays are filled with soil and seeded. Theproduct flow proceeds to the propagation space 2802 where plantsgerminate and are ready for transplant. The plug trays are then conveyedto transplant station 36 of central processing system 30, where theplugs are inserted in crop-bearing modules, such as the plug containersof grow towers 50. The grow towers 50 are inserted into growthenvironment 20 where they proceed from one end to another of the spacealong grow lines 202. Grow towers 50 are then transferred to harvestingstation 32 where the crop is harvested and conveyed to post-harvestprocessing space 2806. The packaged product is ultimately stored in acold storage facility from where it may be ultimately shipped out of thefacility 2800.

The configuration illustrated in FIG. 28 achieves a variety ofoperational and cost efficiencies and advantages. The configuration setforth in FIGS. 28 and 29 essentially bifurcate the system 2800 into autility zone for housing thermal and irrigation equipment, and a plantproduction zone for growing crops. For example, locating propagationspace 2802 and the array of growth environments as shown, allows formost of the thermal, irrigation and nutrient supply equipment to belocated in a single corridor 2800. Growth environments 20 a-f and thespaces associated with central processing system 30 have differentrequirements relative to environmental controls, requiring more precisecontrols for temperature, humidity, air filtration, process isolation,and/or lighting. In addition, given that growth environments 20 a-f andthe spaces associated with central processing system 30 containagricultural product, various food safety requirements may also requireadditional controls, such as process isolation or clean room equipmentto create a space suitable for food/crop production. The layout setforth in FIG. 28 essentially creates a utility zone (nutrient corridor)where it is less expensive to achieve the required controls and aproduction zone where food safety and other requirements mandate tighterenvironmental controls. For example, nutrient and thermal corridor 2820and space 2822 may not be subject to environmental controls and have besubject to ambient temperature and air conditions. In otherimplementations, nutrient and thermal corridor 2820 and space 2822 arecontained in a controlled environment. In addition, the configuration ofFIG. 28 is scalable from both a design standpoint and in connection withexpansion of an existing facility. To build out capacity of the system,additional growth environments can be added to the end of the array ofgrowth environments 20 a-f. Similarly, propagation space 2802 can beexpanded outwardly relative to FIG. 28 .

Materials handling space 2822 is an area of facility 2800 adapted forreceiving supplies and shipping product. As FIG. 29 illustrates, space2822 may be divided into an inbound area 2822 a and outbound area 2822b. Additionally, space 2822 may house any additional electrical ormechanical equipment that does not need to be installed within the cleanor controlled environment of the production facility. In oneimplementation, space 2822 is connected to loading bays including one ormore dock doors for receiving supplies shipped by truck. Receiving space2822 a may be located more proximally to propagation space 2802 andseeding space 2808 in order to reduce the distance traveled for seeds,soil and other supplies consumed by such spaces. Similarly, outboundspace 2822 b may be located more proximally to post-harvest processingspace 2806 and/or the cold storage area to facilitate loading of cropsfor shipment out of the facility. Similarly, the cold storage space mayinclude dock doors allowing for flow of product out of a loading bay.

Although the disclosure may not expressly disclose that some embodimentsor features described herein may be combined with other embodiments orfeatures described herein, this disclosure should be read to describeany such combinations that would be practicable by one of ordinary skillin the art. Unless otherwise indicated herein, the term “include” shallmean “include, without limitation,” and the term “or” shall meannon-exclusive “or” in the manner of “and/or.”

Those skilled in the art will recognize that, in some embodiments, someof the operations described herein may be performed by humanimplementation, or through a combination of automated and manual means.When an operation is not fully automated, appropriate components ofembodiments of the disclosure may, for example, receive the results ofhuman performance of the operations rather than generate results throughits own operational capabilities.

All references, articles, publications, patents, patent publications,and patent applications cited herein are incorporated by reference intheir entireties for all purposes to the extent they are notinconsistent with embodiments of the disclosure expressly describedherein. However, mention of any reference, article, publication, patent,patent publication, and patent application cited herein is not, andshould not be taken as an acknowledgment or any form of suggestion thatthey constitute valid prior art or form part of the common generalknowledge in any country in the world, or that they are discloseessential matter.

Several features and aspects of the present invention have beenillustrated and described in detail with reference to particularembodiments by way of example only, and not by way of limitation. Thoseof skill in the art will appreciate that alternative implementations andvarious modifications to the disclosed embodiments are within the scopeand contemplation of the present disclosure. Therefore, it is intendedthat the invention be considered as limited only by the scope of theappended claims.

What is claimed is:
 1. A crop production facility for controlledenvironment agriculture, comprising: a nutrient and thermal corridor; anarray of one or more grow rooms adjacent to the nutrient and thermalcorridor, the array having a first end and a second end, the arrayextending substantially parallel to the nutrient and thermal corridor;wherein each of the grow rooms comprises one or more grow lines, each ofthe one or more grow lines comprising a grow conveyance mechanism; and aplurality of grow towers, each of the plurality of grow towersvertically attached to, and moveable along, a respective one of the oneor more grow lines; wherein each of the one or more grow lines comprisesa first path section, a second path section, and a return mechanismoperative to transfer grow towers from the first path section to thesecond path section; wherein the grow conveyance mechanism conveys growtowers along the first path section in a first direction, and along thesecond path section in a second direction opposite the first direction;a conveyance mechanism that injects and ejects grow structures from aside of the one or more grow rooms opposite the nutrient and thermalcorridor; a propagation space adjacent to the first end of the array andinterfacing with the nutrient and thermal corridor; and a centralprocessing system comprising one or more grow structure processingsystems adjacent to the array of grow rooms and opposite the nutrientand thermal corridor; wherein one of the one or more grow structureprocessing systems is a harvester station, and wherein the cropproduction facility further comprises a post-harvest processing facilitylocated adjacent to the central processing system and proximal to theharvester station; wherein the harvester station comprises a cropharvesting machine, and a feeder mechanism to receive a grow tower in ahorizontal orientation and feed the grow tower through the cropharvesting machine in a horizontal orientation; and wherein the cropproduction facility further comprises an automated laydown stationcomprising a first robot including an end effector adapted to releasablygrasp a grow tower, and control logic operative to cause the first robotto pick the grow tower from a pick location in a vertical orientation,rotate the grow tower to a horizontal orientation and place the growtower on a conveyor for loading into the harvester station.
 2. The cropproduction facility of claim 1 further comprising a seeding areaadjacent to the propagation space.
 3. The crop production facility ofclaim 1 further comprising a cold storage facility adjacent to thepost-harvest processing facility.
 4. The crop production facility ofclaim 3 further comprising a loading bay adjacent to the cold storagefacility.
 5. The crop production facility of claim 1 further comprisinga conveyor configured to carry bins or harvested product directly on thebelt from the harvester station to the post-harvest processing facility.6. The crop production facility of claim 1 wherein each of the growrooms is substantially encapsulated and comprises one or more controlsystems for controlling one or more environmental variables.
 7. A cropproduction facility for controlled environment agriculture, comprising:a nutrient and thermal corridor; an array of one or more grow roomsadjacent to the nutrient and thermal corridor, the array having a firstend and a second end, the array extending substantially parallel to thenutrient and thermal corridor; wherein each of the grow rooms comprisesa substantially encapsulated growth environment containing a verticalgrow tower conveyance system comprising one or more grow lines, whereineach of the one or more grow lines comprises a first path section, asecond path section, and a return mechanism operative to transfer growtowers from the first path section to the second path section; aplurality of grow towers, each of the plurality of grow towersvertically attached to, and moveable along, a respective one of the oneor more grow lines, wherein each of the plurality of grow towersincludes a plurality of grow sites extending at least along one facethereof; and a grow tower conveyance mechanism operative to convey growtowers along the first path section in a first direction, and along thesecond path section in a second direction opposite the first direction;a central processing system, arranged adjacent to the array of one ormore grow rooms and opposite the nutrient and thermal corridor,comprising a harvester station comprising a crop harvesting machine, anda feeder mechanism to receive a grow tower in a horizontal orientationand feed the grow tower through the crop harvesting machine in ahorizontal orientation; a washing station comprising a second feedermechanism to receive a grow tower in a horizontal orientation and feedthe grow tower through the washing station in a horizontal orientation;a transplanter station comprising a third feeder mechanism to receive agrow tower in a horizontal orientation and feed the grow tower throughthe transplanter station in a horizontal orientation; a plurality ofconveyors arranged to convey grow towers to and from respective ones ofthe harvester station, the washing station and the transplanter station,wherein the plurality of conveyors include a first conveyor arranged tofeed a grow tower to the harvester station, a second conveyor arrangedto feed a grow tower to the washing station, a third conveyor arrangedto feed a grow tower to the transplanter station, and a fourth conveyorarranged to feed a grow tower from the transplanter station to a pickuplocation; and an automated laydown station comprising a first robotincluding an end effector adapted to releasably grasp a grow tower, andcontrol logic operative to cause the first robot to pick the grow towerfrom a pick location in a vertical orientation, rotate the grow tower toa horizontal orientation and place the tower on a conveyor for loadinginto the harvester station; an automated pickup station comprising asecond robot including an end effector adapted to releasably grasp agrow tower, and control logic operative to cause the second robot tograsp a grow tower from the pickup location in a horizontal orientation,rotate the grow tower to a vertical orientation for transfer to a selectgrow line of the plurality of grow lines; and a propagation spaceadjacent to the first end of the array and interfacing with the nutrientand thermal corridor.